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Lincoln Electric Ranger 200, Operator'S Manual

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Ranger 200

OPERATOR’S MANUAL

IM660

January,2000

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part.

DO

NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.

And, most

importantly, think before you act
and be careful.

For use with machines having Code Numbers:

10646

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199  U.S.A.   TEL: 216.481.8100   FAX: 216.486.1751   WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:

This manual covers equipment which is no 
longer in production by The Lincoln Electric Co.  
Specifications and availability of optional 
features may have changed.

Summary of Contents for Ranger 200

Page 1: ...S CONTAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 10646 Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products Date of Purchase Serial Number Code Number Model Where Purch...

Page 2: ...R WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is availa...

Page 3: ...rical earth ground 3 f Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation 3 g Never dip the electrode in water for cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders ...

Page 4: ...event the welding sparks from starting a fire Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Weldin...

Page 5: ...s et non inflammables 4 Des gouttes de laitier en fusion sont émises de l arc de soudage Se protéger avec des vêtements de protection libres de l huile tels que les gants en cuir chemise épaisse pan talons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où l on pique le laitier 6 Eloign...

Page 6: ...he information must be followed to avoid minor personal injury or damage to this equipment CAUTION Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped title passes to the purchaser upon receipt by the carrier Consequently Claims for material damaged in shipment must be made by the purchaser against the transportation company at the time the shipment is receive...

Page 7: ... Recommended Applications B 1 Additional Safety Precautions B 1 Controls and Settings B 1 Welder Controls B 2 Engine Controls B 2 Engine Operation B 3 Before Starting the Engine B 3 Starting the Engine B 3 Stoping the Engine B 3 Welding Operation B 4 DC Stick Welding B 4 DCTIG Welding B 4 Auxiliary Power B 4 Simultaneous Welding and Auxiliary PowerLoads B 5 Extension Cord Recommendations B 5 Acces...

Page 8: ... 5 Storage D 5 Cleaning D 5 Brush Removal and Replacement D 5 Troubleshooting Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 Troubleshooting Guide E 3 Troubleshooting Guide E 4 Wiring Diagram Section F 1 Dimension Print Section F 2 Parts Lists P351 SERIES ...

Page 9: ...re Hydraulic Mechanical Fuel Pump Mechanical Governor with Full Filter 5 Regulation AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION Duel Element Automatic Idler Low noise Muffler Top outlet Shutdown on low oil can be rotated Made from pressure long life aluminized steel ENGINE WARRANTY 2 year unlimited hours See engine manufacturer warranty for details OUTPUT GENERATOR Welding Output Volts at R...

Page 10: ... not operate with doors open or guards off Stop engine before servicing Keep away from moving parts See additional warning information at front of this operator s manual WARNING Always operate the RANGER 200 with the case roof on and all machine components completely assem bled This will protect you from the dangers of moving parts hot metal surfaces and live electrical devices STORING 1 Store the...

Page 11: ...achment to the base of the welding equipment so there will be no undue stress to the framework 3 Proper placement of the equipment on the trailer to insure stability side to side and front to back when being moved and when standing by itself while being operated or serviced WARNING 4 Typical conditions of use i e travel speed rough ness of surface on which the trailer will be operat ed environment...

Page 12: ... prevent ELECTRICAL DAMAGE WHEN a Installing new batteries b Using a booster Use correct polarity Negative Ground The RANGER 200 is shipped with the negative bat tery cable disconnected Make certain that the RUN STOP switch is in the STOP position Remove the two screws from the rear battery tray using a screwdriver or a 3 8 socket Attach the negative battery cable to the negative battery terminal ...

Page 13: ... electrical equipment A machine grounding stud marked with the symbol is provided on the front of the welder WELDING OUTPUT CABLES With the engine off connect the electrode and work cables to the output studs The welding process dic tates the polarity of the electrode cable These con nections should be checked periodically and tightened with a 3 4 wrench WARNING Table A 1 CABLE INSTALLATION Instal...

Page 14: ...electrician should install the machine to a premises or residential elec trical system Be certain that The installation complies with the National Electrical Code and all other applicable electrical codes The premises is isolated and no feedbacking into the utility system can occur Certain state and local laws require the premises to be isolated before the generator is linked to the premises Check...

Page 15: ...RAL BUS GROUND PREMISES DISCONNECT AND SERVICE OVERCURRENT PROTECTION GND N NOTE No 6 COPPER CONDUCTOR CABLE SEE NATIONAL ELECTRICAL CODE FOR ALTERNATE WIRE SIZE RECOMMENDATIONS 240 VOLT GROUNDED CONDUCTOR 25AMP 240 VOLT DOUBLE POLE CIRCUIT BREAKER DOUBLE POLE DOUBLE THROW SWITCH RATING TO BE THE SAME AS OR GREATER THAN PREMISES SERVICE OVERCURRENT PROTECTION 50 AMP 120 240 VOLT PLUG NEMA TYPE 14 ...

Page 16: ...50 Amp 120 240 VAC 14 50R receptacle The 240 VAC receptacle can be split for single phase 120 VAC operation RECOMMENDED APPLICATIONS PROCESSES Excellent DC stick welding GMAW The Ranger 200 can handle up to 3 16 dia 6010 and 7018 elec trodes Can also be used for limited scratch start TIG welding EQUIPMENT K710 Accessory Kit which includes Electrode holder and cable Ground clamp and cable Headshiel...

Page 17: ...TCH RUN position energizes the engine prior to starting STOP position stops the 1 2 3 4 5 6 7 8 10 9 engine The oil pressure interlock switch prevents battery drain if the switch is left in the RUN position and the engine is not operating 6 CHOKE When pulled out it closes the choke valve on the engine carburetor for quick starting 7 START PUSH BUTTON Energizes the starter motor to crank the engine...

Page 18: ... B 3 ENGINE CONTROLS CONTINUED B When the electrode touches the work or power is drawn for lights or tools approximately 100 Watts minimum the engine accelerates and operates at full speed C When welding ceases or the AC power load is turned off a fixed time delay of approximately 12 seconds starts If the welding or AC power load is not restarted before the end of the time delay the idler reduces ...

Page 19: ...The 120 V auxiliary power receptacles should only be used with three wire grounded type plugs or approved double insulated tools with two wire plugs The cur rent rating of any plug used with the system must be at least equal to the current capacity of the associated receptacle NOTE The 240 V receptacle has two circuits each of which measure 120 V toneutral but are of opposite polarities and cannot...

Page 20: ...ent Amps 15 20 15 20 25 Voltag eVolts 120 120 240 240 240 Load Watts 1800 2400 3600 4800 6000 30 60 9 18 40 30 75 60 12 9 23 18 75 50 150 100 90 23 15 46 30 27 125 88 225 175 150 38 27 69 53 46 175 138 350 275 225 53 42 107 84 69 300 225 600 450 250 91 69 183 137 76 Maximum Allowable Cord Length in ft m for Conductor Size Conductor size is based on manimum 2 0 voltage drop 14 AWG 12 AWG 10 AWG 8 A...

Page 21: ...ine when not in use S24647 SPARK ARRESTER Mounts inside exhaust pipe K1690 1 GFCI RECEPTACLE KIT Includes one UL approved 120V ground fault circuit interrupter duplex type receptacle with cover and installation instructions Replaces the factory installed 120V duplex receptacle Each receptacle of the GFCI Duplex is rated at 20 Amps the maximum total cur rent from the GFCI Duplex is limited to the 2...

Page 22: ...the Safety Precautions in the front of this manual and in the Engine Owner s Manual before working on this machine Keep all equipment safety guards covers and devices in position and in good repair Keep hands hair clothing and tools away from the gears fans and all other moving parts when starting operating or repairing the equipment Routine Maintenance At the end of each day s use refill the fuel...

Page 23: ...D PERIODIC ENGINE MAINTENANCE To prevent the engine from accidentally starting dis connect the negative battery cable before servicing the engine See Table D 1 for a summary of maintenance inter vals for the items listed below More frequent service may be required depending on your specific applica tion and operating conditions See the Kubota Engine Operator s Manual for further information OIL Ch...

Page 24: ...inspect the spark plug Discard them if the insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused 5 Measure the plug gap with a feeler gauge Correct as necessary by bending the side electrode Spark Plug Gap 040 in 1 0 mm RANGER 200 6 Check that the spark plug washer is in good condi tion and thread the spark plug in by hand to prevent cross threading 7 After t...

Page 25: ...ight so that none of the solution enters the cells After cleaning flush the outside of the battery the bat tery compartment and surrounding areas with clear water Coat the battery terminals lightly with petrole um jelly or a non conductive grease to retard corro sion Keep the battery clean and dry Moisture accumula tion on the battery can lead to more rapid discharge and early battery failure CHEC...

Page 26: ...hes and slip rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary Do not attempt to polish slip rings while the engine is running Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your facto...

Page 27: ...g the case wrap around cover Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause If you do not under stand or are unable to perform the Recommended Course of Action safely contact you local Lincoln Authorized Field Service Facility HOW TO USE TROUBLESHOOTING GUIDE Service and Repair should only be performed by Lincoln Electric Factory Trained Personne...

Page 28: ...e switch or other engine component 3 Open rotor circuit 1 Faulty battery 2 Loose connections at battery or alternator 3 Faulty engine alternator or charg er modual 1 If all recommended possible areas of misadjustment have been checked and the problem persists Contact your local Lincoln Authorized Field Service Facility 1 Charge Battery 2 Inspect clean and tighten 3 Contact authorized engine Servic...

Page 29: ...uxil iary power 3 Faulty PC board or idler solenoid 1 Poor work lead connection to work 2 Faulty PC board Low idle speed set to low 1 Auxiliary power load is less than 100 watts 2 Faulty PC board 1 Fuel filter clogged 2 Air filter clogged 3 Fouled spark plugs 4 Valves out of adjustment 1 Set switch to Auto 2 Remove all external loads 3 Contact your Local Lincoln Authorized Field Service Facility f...

Page 30: ... 3 Faulty PC board or welder alter nator 1 Faulty control potentiometer or PC board 1 Open circuit breakers 2 Faulty connections to auxiliary receptacles 3 GFCI tripped if installed 4 Faulty PC board or welder alterna tor 1 Remove restriction and allow machine to run until light goes off 2 Use smaller electrode size or slower wire feed speed Allow machine to run until light goes off 1 Make sure wo...

Page 31: ... J3 6 1 5 1 0 J4 J5 3 1 2 4 P7 J7 J10 3 1 2 4 J8 3 1 2 4 J9 1 3 4 6 P11 J11 1 6 8 1 9 P12 J12 6 1 5 1 0 P42 J42 9 1 1 6 P43 J43 3 1 2 4 P41 J41 PCB4 BATTERY PC BOARD PCB2 ANALOG POWER PC BOARD PCB3 WELD CONTROL PC BOARD Programing Mode Selection Machine Selection Meter Meter 6 1 5 1 0 Output Control Hot Start Pinch Arc Force 14 Pin Ampenol Thermal Sense Idler PWM 75 76 77 20 8B 25 1 25 0 26 0A 21 ...

Page 32: ...IMENSION PRINT RANGER 200 M19410 F 2 CENTER OF GRAVITY WITH OIL IN ENGINE AND EMPTY FUEL TANK TRUCK UNDERCARRIAGE MOUNTING HOLES 41 20 17 50 19 50 42 10 20 80 A B 29 88 33 62 36 24 10 28 10 78 7 22 24 86 2 6 ...

Page 33: ...F 3 NOTES F 3 ...

Page 34: ...F 4 NOTES RANGER 200 F 4 ...

Page 35: ...lletin ED 80 or call 216 383 2259 and ask for the Welding School Registrar Lincoln Welding School BASIC COURSE 700 00 5 weeks of fundamentals There is a 10 discount on all orders of 50 00 or more for shipment at one time to one location Orders of 50 or less before discount or orders outside of North America must be prepaid with charge check or money order in U S Funds Only Prices include shipment ...

Page 36: ...electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrode...

Page 37: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 38: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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